Manufacture of vehicles, &amp;c.



trim .s'tra rps i l 3N FFICE.

anueacruee OF vEi-uoLEs. etc.

Specification of Letters Patent.

Patented Oct. 24, 1905 Application filed October 2]., 1904: $crial N0-229,507-

To all whom/ 11/; 'HY/CI/JIV/ concern/.-

Be it known that I, JAoonUs SPYKER, a su bject of the Queen of theNetherlands, residing at Trompenburg, near Amsterdam, Netherlands, haveinvented certain new and useful Improvements in or Relating to theManufacture of Vehicle-Bodies and other Curved or Bent Bodies orArticles, of which the following is a specification.

The present invention relates to the manufacture of vehicle-bodies andother curved or bent bodies or articles, more particularly of so-calledtonneau bodies for motor-cars; but the invention can also be applied tothe manufacture of other curved, spherical, or cylindrical articles,smooth or ornamental, which have to possess a certain degree of rigidityand resistanee such as, for instance, armchairs, seats, basins, baths,pails, balloon-cars, and the like-and it is specially suitable for themanufacture of articles of large dimensions bent or curved in variousdirections.

The object of the invention is to produce such articles at relativelyvery low cost and of great lightness and rigidity.

The invention substantially consists in constructing a non-metallic coreor support of the desired shape and dimensions and in providing thiscore by electrolytic means with a metallic coating of the desiredthickness in order to give it the necessary strength.

An essential part of the invention consists in the method ofconstructing the core or support in such a manner that the latteritself, while being very light, possesses the desired degree of rigidityand resistance and will not lose its shape in the acidulatedelectrolyte. When this core has been made, it is perforated either forits entire extent or only along certain lines traced according to thedirection of the principal curves of the article to be formed, so thatthe electrolytic deposit substantially produces a body consisting of twoplates or the like inclosing the core and connected to each other bymeans of metallic rivets or connect ing-pieces, by which theirconnection with the core or interior support is at the same timestrengthened. In some cases rivets or metal connecting-pieces can beplaced. in the perforations before the electrolytic deposit is formed,and these will subsequently be fixed by means of the said deposit. Theconnection of the two plates in this manner and the difference in theircurvatures, owmg to one of them being on the outside and the other onthe inside of the curved core, cause the plates to assist each other inresisting pressure and bending strains while bearing on the interiorsupport.

In the following description the method for constructing the core orinterior support will be described in detail.

To construct the core or support, a matrix or moldjs first made theinner surface of which, either smooth or ornamental, has the shape ofthe vehicle-body or the like to be constructed. This inner surface ismoistened with water by suitable means, and strips of paper are thenapplied thereto, the length and breadth of the said strips beingdependent on the radii or shape of the matrix curves, which they mustcover smoothly without folds. The paper strips are aflixed in such amanner that they cross one another in superposed layers in order to giveresistance along the different curves. Each layer is provided with acoating of isinglass, gelatin, or the like, to which acert-ain quantityof bichromate of potassium has been mixed. After each application ofglue or the like the interior of the moldthat is to say, the coatingapplied to the said interior-is illuminated by means of a powerfulelectric furnace, producing a white light, which acts on thebichromate'of potassium in such a manner as to fix" the glue and renderit insoluble in water. A layer of vegetable fiber or fabric, preferablywith large meshes, is then applied to the paper and glue, this fabricbeing arranged in the same manner as the paper-that is to say, in theshape of crossed bands or strips. Good results have been obtained bymeans of narrow bands of fabric. It is, however, preferable to use bandsmade of natural fibrous or ligneous ma terial, which can be obtained bybeating and. flattening small strips of wood or bark peeled from certaintrees. \Vhen these strips have been sufliciently flattened, they havethe appearance of coarse wide-meshed fabric, having a certain degree ofelasticity, as well as considerable resistance of traction. The strengthof this natural fabric evidently depends on the nature of the fiber andof the texture of the wood from which the strip has been peeled.Particularly supple and resistant materials of this kind are known tocommerce, and they are manufactured from the beaten, pressed, andflattened bark of certain trees, such as the kajoe terep (Arzfocmpuschat ice) and the atap.

As already stated, it is of great advantage to use beaten bark insteadof fabric. The choice of the artificial or natural tissue depends asmuch on its texture, size of the meshes, and so on, as on its strength,since it is of great advantage for the manufacture that the said tissueshould absorb a large quantity of glue. The bark of the kajoe terep orthe atap or thelike is applied in the same manner in the form of narrowcrossed bands. To the layer of artificial fabric or natural tissue(beaten bark) a thick layer of bichromated glue is applied, which isalso illuminated in order to be fixed and rendered insoluble in water.Upon the layer of fabric or bark and glue another layer of paper isplaced and on the latter another coating of glue, which is fixed bymeans of light, and the body thus built up can then be removed from themold. Finally, bichromated glue is aflixed to the exterior surface ofthe paper which was in contact with the mold, and this glueis also fixedin the manner described. The rigid core or support is then complete.Before fixing the two first coatings of glue it is desirable in order toproduce intimate connection between the various elements of each layerwith its coating of glue to applypowerful pressure. Since, however,curved outlines are frequently very complicated, it is impossible to useswages or dies for this purpose, so the mold or matrix, with the layersthereon. is introduced into a closed chamber of a suitable height, and asuitable quantity of sand is then poured into the said chamber,whereupon hydraulic pressure can be applied. After being subjected tothis pressure the core is of course thinner and stronger than if it hadbeen simply glued. In any case, however, the core or support is verylight and combines with a certain degree of elasticity the desiredrigidity and resistance which enables it to resist impacts, shocks, andthe like without becoming dented or distorted, as would be the case withsheet-aluminium or the like. The manufacture is very easy and rapid. Inmanufacturing cores for motor-car bodies the seat can in some cases bemade in one piece with the back of the body. The thickness of the corealso depends on the number of layers of each material used in itsmanufacture. Experience has shown that three single layers -namely,paper, fabric, or bark and paperwith coatings of glue Were sufiicientfor the production of a very rigid and resistant core.

The core thus built up is pierced with small holes, as has beenmentioned above, and is then prepared in the known manner for theelectrolytic deposit by coating its surface with plumbago or carbon. Thecore is then introduced in the electrolytic bath, in which it remainsfor the length of time necessary to obtain a deposit of sufficientthickness to give the required rigidity and resistance. The

metallic plates which are formed upon the two surfaces opposed areconnected to each other by means of connecting pieces or rivets formedin the holes by the electrolytic deposit. Since the core resists theaction of acid ulated water, it is not damaged in the bath. The metallicdeposit preferably used is a deposit of copper. When the body is removedfrom the electrolytic bath, it consists, therefore, substantially of twometallic plates of different curvature connected to one another bycross-pins or the like and inclosing a core or support to the shape ofwhich they correspond. These various elements are cooperating factorswhich are combined with the object of imparting to the product,notwithstanding its great lightness, slight thickness, and extensivecurvature, the desired rigidity and resistance which will enable it towithstand the mechanical influences-such as pressure, bending strains,impacts, shocks, vibrations, and the like--and also physical influences,such as change of temperature, heat, cold, moisture, and the like. Themetallic coating can of course be provided with a coating of paint orvarnish or can be plated with gold, silver, bronze, or the like.

lVhat I claim as my invention, and desire to secure by Letters Patent,is

1. The method of manufacturing vehiclebodies and the like consisting offirst constructing a core of any desired contour, perforating the same,and providing the core by electrolytic means, with metallic connectingportions within the perforations and a metallic cover formed with saidportions.

2. The method of manufacturing vehicle bodies and the like consisting offirst constructing a core of afiixed layers of non-metallic material,perforating the same, and subsequently providing the core byelectrolytic means with a metallic covering and with metallic connectingmeans within the perforations.

3. The method of manufacturing vehiclebodies and the like consisting offirst constructing a core of affixed layers of non-metallic materialadapted to resist the action of water, perforating the same, andsubsequently providing the core by electrolytic means, with a metalliccovering and with metallic connecting portions Within the PET.forations.

l. The method of producing vehicle-bodies and the like consisting offirst forming a layer of paper bands, covering it with glue, applying alayer of fabric, covering it with glue, applying a second layer ofpaper, then covering the entire product with glue and finally providingsaid product, by electrolytic means with ametallic coating.

5. The method of producing vehicle-bodies and the like consisting offirst forming a layer of paper bands, then applying a layer of fabricand then a layer of paper, said layers being affixed one to the other bychromated glue which is subjected to light subsequent to itsapplication, then covering the product with chromated glue, subjectingit to the action of light, and providing the product by electrolyticmeans with a metallic coating.

6. The method of producing vehicle-bodies and the like consisting offirst applying to a mold a n'lultiplicity of successive layers of fabricand glue, placing the mold and layers in a chamberand finally pressing acolumn of sand into the chamber, said sand adapting itself to the shapeof the layers and subjecting them to uniform pressure. p

7. As a new product, vehicle-bodies and other curved bodies consistingof two electrolytically-deposited metallic plates of different curvatureconnected to each other by means of connecting pieces or rivets andinclosing a light core or support constructed of crossed paper stripsand strips of fabric or tree-bark With interposed coatings of bichro 9.As a new article of manufacture a bod consisting of a core of superposedlayers of paper and wood with fixed ehromated glue therebetween, saidcore being perforated, and a metallic cover deposited upon all surfacesof the core and within the perforations.

In witness whereof I have hereunto set my hand in the presence of twowitnesses.

JACOBUS SPYKER.

Witnesses:

GERRIT ABRAHAM voN HUNTELN, AUGUST SIEGFRIED Down.

